Part 5/13:
Heat Shield and Structural Innovations
Musk delves into the engineering challenges of reusability, notably the development of heat shields made from stronger tiles that are roughly twice as robust as previous versions. The goal is to prevent tile loss and improve durability, which was a significant issue in prior flights where tiles cracked or shed.
The transition from carbon fiber to stainless steel for the main fuselage was driven by cost, ease of manufacturing, and thermal properties. Steel’s resilience at high temperatures and weldability make it advantageous, especially considering that reusability requires parts to withstand extreme re-entry heat without excessive heat shielding mass.